Spring assembly



April 1963 0. LEVINE 3,084,353

SPRING ASSEMBLY Filed April '7, 1961 United States Patent 3,084,353SPRING ASSEMBLY David I. Levine, Swampscott, Mass, assignor to SpringPfigIdllCtS Developing Co., Swampscott, Mass, a partner- P Filed Apr. 7,1961, Ser. No. 101,493

5 Claims. (Cl. 5-248) This invention relates to a coil spring assemblymade up of a multiplicity of coil springs for use in the fabrication ofmattresses, upholstered furniture and the like.

It is an object of this invention to provide a coil spring assembly inwhich the individual coil springs are spaced from one another but areinterconnected in a novel and improved manner which deters inadvertentdisplacement of the coils from their positions in aligned rows andcolumns while providing a desired degree of firmness and enabling theflexing of the spring coils in the necessary manner.

In the improved spring assembly constructed in accordance with theinvention there are provided successive spaced rows of helically coiledsprings wherein the springs in each row are spaced from one another andare substantially aligned with corresponding springs in the adjacentrows. Thus the spring coils may be said to be aligned in spaced columnsand rows. A heavy gauge border wire extends continuously around theperiphery of the coil springs in the plane of the top surfaces of thecoils to define a plane surface of the spring assembly. The border wireis secured to the coils by a spiral wire member that is positioned overthe border wire and has loop portions which engage in securingrelationship of upper ring portions of the peripheral coils in thespring assembly. A first tie wire which is substantially straight buthas loop configurations disposed in it at spaced intervals extend alongthe peripheral portions of coils in each column in both the top andbottom planes of the spring assembly with each loop configurationengaging the top or bottom ringas the case may be in the column withwhich that tie wire is associated. The loop configuration is formed toprovide two spaced loops of wire disposed generally perpendicularly tothe axis of the tie wire and a third loop disposed parallel to the axisof tie wire but laterally spaced therefrom. The ring portion of thespring coil is disposed in the space between the two loops and the thirdlaterally dis-placed loop with the laterally displaced loop preferablybeing disposed outwardly of the periphery of the coil. A straight tiewire is associated with each row of coils and extends through theseveral laterally spaced loops in a direction perpendicular to thelooped tie wire and above the ring portions and the two tie wirescooperate to secure each coil on the tie wires. A wire link extendsbetween two spaced coils in adjacent columns and passes through theother loops of the first tie wires so that it maintains these coils inproper spaced columnar relationship, inhibits any tendency for them toslide along the straight tie wires and integrates the end rings in aflexible yet firm plane. These wire links are preferably disposedparallel to and in substantial alignment with the straight tie wires. Inthis manner the invention provides a simple, firm and resilient assemblyof coil springs which enables the use of fewer spring coils of heaviergauge wire than heretofore employed in similar types of coil springassemblies and thus enables the provision of 'a more economical springassembly which is functionally equivalent to more complex andsubstantially more expensive spring assemblies such as those in whichportions of the top and bottom rings of adjacent coils are juxtaposed.

Other objects, features and advantages of the invention will be seen asthe following description of the preferred embodiment thereofprogresses, in conjunction with the drawing, in which:

FIG. 1 is a top plane view of a portion of a coil spring assemblyembodying principles of this invention;

FIG. 2 is a sectional view taken along the lines 2-2 of FIG. 1 showingthe configuration and the arrangement of the tie wires and a wire linkemployed in' the construction shown in FIG. 1;

FIG. 3 is a sectional view taken along the lines 33 of FIG. 1 showing asecond view of the assembly of tie wires and link wire;

FIG. 4 is a sectional view taken along the lines 4-4 showing stillanother view of the relationship of the several coil spring positioningwires;

FIG. 5 is a perspective view of the configuration of the tie wires andlink wire at their point of intersection with a ring portion of a springcoil; and

FIG. 6 is a perspective view of a portion of an illustrative springassembly constructed in accordance with principles of the invention.

The spring assembly in which the invention is practiced may incorporatethe particular hour glass form of spiral compression coil springs 10shown in FIGS. 1 and 6, with each coil formed to define an upper ringportion 12 and a lower ring portion 14. The assembly may be made byplacing the coil springs on a suitable block or form equipped with pinsfor holding the spring coils in the desired row and column relationshipas they are being secured at their end ring convolutions 12, 14 by thetie wire elements 16, 1 8 and links 20. It will be noted that each endof the coil wire is secured to the portion of the helical coil to form aring so that two spaced planar surfaces are defined by those rings whenthe coils are positioned in spaced rows extending lengthwise andcrosswise with the end ring convolutions forming top and bottom planesof the spring assembly.

A first tie wire element 16 has sets of three loo'ps 22, 24, 26 formedin it at spaced intervals. A first loop or U-shaped bend 22 is formedwhich extends parallel to the direction (axis) of the tie wire 16 and isoffset laterally from the axis of the tie wire 16 and is bent upwardlyfrom that axis. The wire 16 is additionally bent to form two S-shapedportions as shown best in FIG. 2 with two loop portions 24, 26 whichrise above the wire and are disposed substantially perpendicular to theaxis of the wire. Two depressions 28, 30 between the offset loop 22 andeach loop portion 24, 26 respectively result. This S-configured doubleloop may be formed in a series of successive shaping operations and ispositioned at spaced intervals along the tie wire 16 equal to thedesired spacing between the centers of the coils in the several columns.The tie wire is disposed so that a portion of the end ring 12 (or 14) ispositioned in the depressions 28, 30 between the three loops, with theoffset loop 22 being positioned outwardly of the margin of the ring asindicated in FIGS. 16. A looped tie wire 16 is positioned along eachmargin portion of the coil rings so that two wires 16 are associatedwith each column of coil rings.

Cooperating straight tie wires 18 are then threaded through the offsetloop 22 and over the ring wire 12 (or 14) so that the coil is secured tothe tie wire 16 at opposite edges of the ring as indicated in FIGS. 1and 6. The straight tie wire is aligned with the centers of the coils 10in the associated row. Where the coils are connected in juxtaposedrelation the two tie wires adequately secure them and prevent movementalong the straight wire '18 but in this simplified spaced relation theyare not inhibited from movement along that tie wire. To secure the coilsin the desired inter-related positions and to inhibit relative movementa link wire 20 is provided which has a straight length 32 substantiallyequal to the desired spacing between adjacent columns of coils and aloop 34 formed in either end thereof. Each loop 34 of this link 20 isinserted through the loops 24, 26 in tie wire 16, passing under thestraight tie wire 18 and over the end convolution '12 (or 14) with thestraight link portion extending between the marginal portion of an endring in one column and the marginal portion of the end ring in theadjacent row as indicated in FIG. 1. This link thus clamps the assembledwires together in a more securerelationship and at the same timeprovides a fixed limit for the several coils 10 in their columnarpositions.

The wires 20 may be inserted in place sliding the coils along the tiewires 18 toward one another. The several link wires 20 are positioned asindicated in FIGS. 1 and 6 and then the outer peripheral portions of thecoil assembly are urged apart so that the link wire assemblies areforced tightly into engagement with the loop portions of the looped tiewire 16. The peripheral portions of the coil assembly are then securedto the firm border wire 36 which extends around the periphery of thecoil assembly in the plane of the upper coil rings 12 by means of ahelical wire 38 which flexibly and firmly interlocks and encompassesmarginal portions of the upper and end ring convolutions '12 and theborder Wire 36. The border wire and cooperating helical wire 38 thusserve in the spring assemblies as a border element which tends to resistmisalignment of the assembly and to better define the plane surface ofthe spring, especially when the assembly meets with impact on anintermediate area of the spring assembly. The looped tie wires 16terminate short of the border wire 36 while the upper straight tie wires18 are looped over the border wire at their ends and the ends of thelower straight tie wires 18 are looped over the inner portions of thelower rings 14 to secure them in place, as indicated in PEG. 6.

The coil springs of the adjacent rows thus are secured together in asimple but integrated assembly utilizing tie wires and link wires whichcoact to provide firm yet properly resilient support so that compressingand distorting forces impressed on particular areas of the springassembly do not tend to cause the individual coil spring elements toseparate from one another or to otherwise become misaligned since eachend ring convolution is firmly locked in place and secured in spacedrelationship from the adjacent end ring convolutions. The link or spacerwires 20 integrate each plane surface of the coil assembly and permitmanufacture of a box spring founda tion for mattresses, studio couchesor other furniture with less coils of a heavier gauge wire, thuseffecting a considerable reduction in cost. This inexpensive spacer wireis easily assembled with the coils and remains securely fastened merelyby threading through tie wire loops associated with spaced columns ofcoil springs. It enables omission of some coils, spans the openingsbetween remaining spaced coils and produces a firm spring assembly. Theinvention also enables selected portions of the spring assembly to bemade stitler, if desired. For example, the outside coils of the springassembly may be arranged to overlap one another and the balance of thecoils assembled with sp acer links which have lengths corresponding tothe diameters of the coils that they replace. Similarly, the center ofthe spring assembly construction may be made stiffer by using additionalcoils in that area in place of spacer links. Thus the invention providesan inexpensive spring assembly which uses fewer coils, is lighter inweight and yet provides the firm and trouble free support that isdesired of spring assemblies.

While a preferred embodiment of the invention has been shown anddescribed it will be understood by those skilled in the art that variouschanges may be made therein and therefore it is not intended that theinvention be limited to the described embodiment or to details thereofand departures may be made therefrom within the spirit and scope of theinvention as defined in the claims.

I claim:

I. A spring assembly comprising a plurality of coil springs arranged ina series of columns and rows, each said coil spring being spaced fromthe coil springs in the adjacent columns and rows and having an upperend ring convolution and a lower end ring convolution with said coilsprings disposed so that all the upper end ring convolutions lie in afirst plane and all the lower end ring convolutions lie in a secondplane which planes respectively define the upper and lower surfaces ofthe spring assembly, a series of first tie wires disposed parallel tosaid columns, each said first tie wire having a plurality of sets ofloop portions connected by straight portions of said tie wire, said setsof loop portions being spaced along each said tie wire at intervalsequal to the spacing between centers of coil springs in adjacent rows,each set of loops including a first upstanding offset loop disposedsubstantially parallel to the axis of said tie wire and two cooperatingupstanding loops disposed substantially perpendicular to the axis of thetie wire, said cooperating loops being disposed on either side of saidoffset loop between said offset loop and the connected straight portionof said tie wire and being formed to provide a depression between eachcooperating loop and the offset loop in each said set, a portion of eachend ring convolution disposed in said depressions between said ofisetloop and the cooperating loops of each tie wire associated with thecolumn of coil springs, a group of straight tie wires disposedperpendicularly to said first tie wires and passing across the centersof each row of coils, each said straight tie wire being passed throughall the offset loops associated with each plane in the associated row ofcoils and over the associated end ring convolutions of the coils thatare disposed in said depressions, and a plurality of link wires eachhaving a straight portion and two end loop portions lying substantiallyin a single plane, one end loop portion of each said link wire passingthrough said two cooperating loops of one of the first tie wires and theother loop of the link wire passing through the cooperating loops in atie wire associated with the next adjacent column of coils so that theend ring convolutions are clamped securely in the depressions formed insaid first tie wire and movement of said coils toward one another isrestrained without inhibiting the flexing and support action of saidspring assembly.

2. The spring assembly as claimed in claim 1 wherein said link wiresextend parallel to rows of coil springs.

3. A spring assembly comprising a plurality of coil springs arranged ina series of columns and rows, each said coil spring being spaced fromthe coil springs in the adjacent columns and rows and having an upperend ring convolution and a lower end ring convolution with said coilsprings disposed so that all the upper end ring convolutions lie in afirst plane and -all the lower end ring convolutions lie in a secondplane which planes respectively define the upper and lower surfaces ofthe spring assembly, a border wire extending continuously about the coilsprings adjacent the peripheral edges of the upper end ring convolutionsof the outer coil springs, means interconnecting the border wire withthe adjacent portion of the upper end ring convolution of the outer coilsprings, a series of first tie wires disposed parallel to said columns,each said first tie wire having a plurality of sets of loop portionsconnected by straight portions of said tie wire, said sets of loopportions being spaced along each said tie wire at intervals equal to thespacing between centers of coil springs in adjacent rows, each set ofloops including a first upstanding loop disposed substantially parallelto the axis of said tie wire and two cooperating upstanding loopsdisposed substantially perpendicular to the axis of the tie wire, saidcooperating loops being disposed on either side of said ofiset loopbetween said offset loop and the connected straight portion of said tiewire and being formed to provide a depression between each cooperatingloop and the offset loop in each said set, a portion of each end ringconvolution disposed in said depressions between said otlset loop andthe cooperating loops of each tie Wire associated with the column ofcoil springs, a group of straight tie wires disposed perpendicularly tosaid first tie wires and passing across the centers of each row ofcoils, each said straight tie wire being passed through all the offsetloops associated with each plane in the associated row of coils and overthe associated end ring convolutions of the coils that are disposed insaid depressions, the straight tie wires associated with said upper endring convolutions secured to said border wire, and a plurality of linkwires each having a straight portion and two end loop portions lyingsubstantially in a single plane, one end loop portion of each link wirepassing through said two cooperating loops of one of the first tie wiresand the other loop portion of said link wire passing through thecooperating loops in a tie wire associated with the next adjacent columnof coils so that the end ring convolutions are clamped securely in thedepressions formed in said first tie wire and movement of said coilstoward one another is restrained without inhibiting the flexing andsupport action of said spring assembly.

4. A spring assembly comprising a plurality of coil springs arranged ina series of columns and rows, each said coil spring being spaced fromall of the other coil springs and each spring having an upper end ringconvolution and a lower end ring convolution, said coil springs beingdisposed so that all the upper end ring convolutions lie in an upperplane and all the lower end ring convolutions lie in a lower plane whichplanes define two surfaces of the spring assembly, a first group of tiewires disposed parallel to said columns of coil springs, each said firsttie wire having a plurality of sets of loop portions formed therein andconnected by straight portions of said tie wire, said sets of loopportions being spaced along said tie wire at intervals equal to thespacing between centers of coil springs in adjacent rows, each said setof loops including a first offset loop disposed substantially parallelto the axis of said tie wire and two cooperating upstanding loopsdisposed substantially perpendicular to the axis of the tie wire, saidcooperating loops being disposed on either side of said ofiset loopbetween said oiiset loop and the connected straight portion of said tiewire and being formed so that a depression is provided between eachcooperating loop and the ofiset loop in each set, said first tie wiresbeing disposed so that said sets of loop portions are substantiallyaligned with the centers of said coils aligned in rows with the portionof each end ring convolution generally tangential to the column andfacing another column of coils spaced therefrom being disposed in thetwo depressions between said ofiset loop and the cooperating loops witheach said ofiset loop disposed outwardly of said end ring convolution, agroup of straight tie wires disposed perpendicularly to said first tiewires and passing through the offset loops associated with each plane inthe associated row of coils and over the associated end ringconvolutions of the coils that are disposed in said depressions, and aplurality of link wires, each having a straight portion and two end loopportions lying substantially in a single plane, one end loop portion ofeach link wire passing through said two cooperating loops of one of thefirst tie wires and the other loop of said link wire passing through thecooperating loops in a tie wire associated with the next adjacent columnof coils with said straight portion disposed parallel to the straighttie wire associated with that row of coils, each said link wire looppassing under said straight tie wire and over said end ring convolutionto clamp the end ring convolution securely in the depression formed insaid first tie wire so that movement of said coils toward one another isrestrained without inhibiting the flexing and support action of saidspring assembly.

5. A spring assembly comprising a plurality of coil springs arranged ina series of columns and rows, certain of said coil springs being spacedfrom coil springs in adjacent columns and rows and each said coil springhaving an upper end ring convolution and a lower end ring convolution,said coil springs being disposed in said assembly so that all said upperend ring convolutions lie in a first plane and all said lower end ringconvolutions lie in a second plane, which planes respectively define theupper and lower surfaces of said spring assembly, a series of tie wiresdisposed substantially parallel to said columns, each said tie wirehaving a plurality of sets of upstanding loop portions connected bystraight portions of said tie wire, said sets of loop portions beingspaced along each said tie wire at intervals equal to the spacingbetween centers of the coils in adjacent rows, each set of loopsincluding first and second upstanding loops laterally spaced from oneanother such that a depression is formed therebetween so that theportion of an end ring convolution may be disposed in said depressionbetween said two upstanding loops, and a plurality of spacer Wires, eachsaid spacer wire having two end loop portions and a straight linkingportion connecting said end loops, said end loop portion being formed bya bend adjacent the end of the spacer wire so that the direction of eachWire end is reversed and it is disposed substantially parallel to saidstraight portion but spaced therefrom, one end loop portion of eachspacer wire passing through the tie wire loop disposed interiorly of anend ring convolution of a first coil spring with both the straight linkportion and the end of the spacer wire associated with said one end loopportion disposed above the end ring convolution so that the end ringconvolution is clamped securely in the depression in said first tie wireand the opposite end loop portion passing through a tie wire loopdisposed interiorly of an end ring convolution of a coil spring in thenext spaced column from said first coil spring with said straight linkportion and the end of the spacer wire associated with the opposite endalso disposed above the end ring convolution, said spacer wiremaintaining said coils in proper spaced relation without inhibiting theflexing and support action of said spring assembly.

References Cited in the file of this patent UNITED STATES PATENTS 694,614 Closterman Mar. 4, 1902 2,314,050 Levine Mar. 16, 1943 FOREIGNPATENTS 515,821 Great Britain Dec. 14, 1939 744,015 Great Britain Jan.25, 1956

1. A SPRING ASSEMBLY COMPRISING A PLURALITY OF COIL SPRINGS ARRANGED INA SERIES OF COLUMNS AND ROWS, EACH SAID COIL SPRING BEING SPACED FROMTHE COIL SPRINGS IN THE ADJACENT COLUMNS AND ROWS AND HAVING AN UPPEREND RING CONVOLUTION AND A LOWER END RING CONVOLUTION WITH SAID COILSPRINGS DISPOSED SO THAT ALL THE UPPER END RING CONVOLUTIONS LIE IN AFIRST PLANE AND ALL THE LOWER END RING CONVOLUTIONS LIE IN A SECONDPLANE WHICH PLANES RESPECTIVELY DEFINE THE UPPER AND LOWER SURFACES OFTHE SPRING ASSEMBLY, A SERIES OF FIRST TIE WIRES DISPOSED PARALLEL TOSAID COLUMNS, EACH SAID FIRST TIE WIRE HAVING A PLURALITY OF SETS OFLOOP PORTIONS CONNECTED BY STRAIGHT PORTIONS OF SAID TIE WIRE, SAID SETSOF LOOP PORTIONS BEING SPACED ALONG EACH SAID TIE WIRE AT INTERVALSEQUAL TO THE SPACING BETWEEN CENTERS OF COIL SPRINGS IN ADJACENT ROWS,EACH SET OF LOOPS INCLUDING A FIRST UPSTANDING OFFSET LOOP DISPOSEDSUBSTANTIALLY PARALLEL TO THE AXIS OF SAID TIE WIRE AND TWO COOPERATINGUPSTANDING LOOPS DISPOSED SUBSTANTIALLY PERPENDICULAR TO THE AXIS OF THETIE WIRE, SAID COOPERATING LOOPS BEING DISPOSED ON EITHER SIDE OF SAIDOFFSET LOOP BETWEEN SAID OFFSET LOOP AND THE CONNECTED STRAIGHT PORTIONOF SAID TIE WIRE AND BEING FORMED TO PROVIDE A DEPRESSION BETWEEN EACHCOOPERATING LOOP AND THE OFFSET LOOP IN EACH SAID SET, A PORTION OF EACHEND RING CONVOLUTION DISPOSED IN SAID DEPRESSIONS BETWEEN SAID OFFSETLOOP AND THE COOPERATING LOOPS OF EACH TIE WIRE ASSOCIATED WITH THECOLUMN OF COIL SPRINGS, A GROUP OF STRAIGHT TIE WIRES DISPOSEDPERPENDICULARLY TO SAID FIRST TIE WIRES AND PASSING ACROSS THE CENTERSOF EACH ROW OF COILS, EACH SAID STRAIGHT TIE WIRE BEING PASSED THROUGHALL THE OFFSET LOOPS ASSOCIATED WITH EACH PLANE IN THE ASSOCIATED ROW OFCOILS AND OVER THE ASSOCIATED END RING CONVOLUTIONS OF THE COILS THATARE DISPOSED IN SAID DEPRESSIONS, AND A PLURALITY OF LINK WIRES EACHHAVING A STRAIGHT PORTION AND TWO END LOOP PORTIONS LYING SUBSTANTIALLYIN A SINGLE PLANE, ONE END LOOP PORTION OF EACH SAID LINK WIRE PASSINGTHROUGH SAID TWO COOPERATING LOOPS OF ONE OF THE FIRST TIE WIRES AND THEOTHER LOOP OF THE LINK WIRE PASSING THROUGH THE COOPERATING LOOPS IN ATIE WIRE ASSOCIATED WITH THE NEXT ADJACENT COLUMN OF COILS SO THAT THEEND RING CONVOLUTIONS ARE CLAMPED SECURELY IN THE DEPRESSIONS FORMED INSAID FIRST TIE WIRE AND MOVEMENT OF SAID COILS TOWARD ONE ANOTHER ISRESTRAINED WITHOUT INHIBITING THE FLEXING AND SUPPORT ACTION OF SAIDSPRING ASSEMBLY.